Method for embedding a distinguishing aesthetic and/or functional surface feature into a panel surface

Abstract

A method for embedding a distinguishing aesthetic and / or functional surface feature into a panel surface is described. An open mesh sheet of material is applied to a mold surface and plastic applied to the mold surface and to the back side of the open mesh material. The plastic forms a shell that is then removed from the mold with the open mesh material at least partially embedded in the surface of the shell. The shell then may be used as a trim panel that includes the aesthetic and functional features of the open mesh material.

Description

TECHNICAL FIELD OF THE INVENTION [0001] This invention relates generally to molding and, more particularly, to a method for embedding a distinguishing appearance and / or functional surface feature into the surface of a molded panel. BACKGROUND OF THE INVENTION [0002] It is known for panels to include embedded color features that have outer surfaces that lie flush with outer surfaces of the panels they are embedded in. One current process for producing such products includes forming a feature on a slush mold surface, then casting a charge of powdered plastic against the mold and a back surface of the color feature. [0003] One example of this process is disclosed in U.S. Pat. No. 5,648,030 issued Jul. 15, 1997 to Pemberton et al. According to Pemberton et al., the color feature is formed by first placing a stencil on the mold surface then casting a plastic powder into the stencil. The stencil is then removed before the second charge of plastic is cast. The formation of the feature on t...

AI Technical Summary

Benefits of technology

[0016] In accordance with this invention, a process is provided for embedding a distinguishing appearance and / or functional surface feature into a surface of a plastic shell, preferably for an automotive trim panel, wherein the feature is made from a pliable open mesh sheet of preferably plastic material which is placed onto a mold surface before casting or forming the plastic shell. A mold comprises a mold surface having a shape complementing a desired shape of the surface of the plastic shell to be molded. A pliable open mesh sheet, preferably of plastic material, is placed onto the heated mold surface and generally conforms to the mold surface due to the compositional nature of the sheet or by other means. A quantity of plastic, in liquid, particulate or melt form is then applied against the mold surface and the back surface of the open mesh sheet of preferably plastic material. This causes the open mesh sheet to further conform to the mold surface but also allows the liquid, powder or polymer melt to at least partially penetrate the interstices of the open mesh. The resulting composite shell including a distinguishing appearance feature is then cooled and removed from the mold surface with the distinguishing appearance feature embedded in the surface of the shell. Designs formed on shell surfaces in this way are durable in that they are not as susceptible to being worn off as are surface coatings such as paint. Because the design is embedded in the shell, colors and / or color shades that distinguish the feature from the surrounding shell surface are more likely to last the lifetime of the shell. An embedded feature produced by the inventive process is distinguishable from the surrounding shell surface not only by visual differences such as color or shade and pattern, therefore providing more design freedom for the stylist, but also the by the nature of the surface (e.g. non-skid) of the open mesh sheet. This may further provide a similar condition, or property, to the surface of the finished plastic shell as the outer surface of the open mesh sheet is at least partially exposed, generally at the intersections of the mesh pattern.

[0017] Thus, according to another aspect of the invention, the open mesh sheet of preferably plastic material has a surface condition or property that is the different from the surface condition or property of the plastic that is cast or applied against the mold to form the main body of the plastic shell. By using the open mesh material to form a portion of the surface of the plastic skin or shell, the specific property (e.g. non-skid nature, high friction, gripping) may be transferred to or included in the shell material and provide a unique property as well as unique appearance within the shell.

Problems solved by technology

The formation of the feature on the mold ties up molds for an excessive period of time and is labor intensive.

In addition, to accurately cast plastic powder exclusively into the confines of a stencil on a mold surface requires additional tooling and / or labor to prevent the powder from falling onto other portions of the mold.

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